Compressor system for a process gas plant having heat return, and the process gas plant for carbon dioxide gas separation

ABSTRACT

A compressor system is provided for a process gas plant having heat return. The system includes compressor for compressing a moist process gas. A process gas cooler unit is connected downstream of the compressor for cooling the process gas and includes two gas coolers. The two process gas coolers are connected directly one after the other in an upstream-downstream manner on a process gas side. The two process gas coolers are operable to provide that, first of all, a predetermined heat flow is removable from the process gas from the upstream process gas cooler, to cause a thermodynamic state of the process gas between the first and second process gas coolers to be in the region of the dew point front, and secondly, that the process gas is capable of being cooled to a predetermined temperature by the downstream process gas cooler.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is the US National Stage of International Application No. PCT/EP2010/054272, filed Mar. 31, 2010 and claims the benefit thereof. The International Application claims the benefits of German application. No. 10 2009 015 861.8 DE filed Apr. 1, 2009. All of the applications are incorporated by reference herein in their entirety.

FIELD OF INVENTION

The invention refers to a compressor system for a process plant having heat return, and the process plant for carbon dioxide gas separation having the compressor system.

BACKGROUND OF INVENTION

During the combustion of fossil fuels, especially carbon dioxide gas results as flue gas and is to be seen as loading the environment if the carbon dioxide gas is discharged into the atmosphere. In particular, a fossil power plant emits considerable quantities of carbon dioxide gas, which it is necessary to reduce. To this end, a method is known in which the carbon dioxide gas emission of the power plant is separated from the flue gas, compressed and stored underground. For separating the carbon dioxide gas from the flue gas, a carbon dioxide gas separation plant, which has a compressor unit for compressing the carbon dioxide gas, is known. The compressor unit has a compressor having a multiplicity of compressor stages with which the carbon dioxide gas is compressed in stages. As a rule, the carbonaceous gas is moist since water is produced during the combustion of the fossil fuels.

The compression of the carbon dioxide gas takes place in the compressor polytropically and, in proportion to the pressure ratio of the compressor, leads to a temperature increase of the carbon dioxide gas. The compressor can be constructed from a multiplicity of compressor stages, wherein after the individual compressor stages the carbon dioxide gas is cooled by means of a cooler. As a result, the effort which is required for driving the compressor can be reduced.

In the cooler, heat from the carbon dioxide gas is yielded to a cooling medium. Cooling water, which flows through the cooler in a cooling water circuit, is conventionally used as the cooling medium, wherein heat is extracted from this for tempering the cooling water. For increasing the thermal efficiency of the carbon dioxide gas separation plant, it is advantageous to feed the heat, which is removed from the cooling water, to the process of the carbon dioxide gas separation plant at a suitable point. For example, two cooling water circuits with different temperature levels are provided in the carbon dioxide gas separation plant, wherein the cooling water circuit with the higher temperature level is provided for cooling the carbon dioxide gas directly after discharging from the compressor stage. For cooling the cooling water in this cooling water circuit, industrial water, for example, can be heated. The cooling water circuit with the lower temperature level is then used for further cooling of the carbon dioxide gas to a required temperature level which, for example, is suitable for entry of the carbon dioxide gas into the next compressor stage.

The cooler conventionally has a housing which is exposed to admission of the carbon dioxide gas and in which two cooler bundles are accommodated, wherein one of the cooler bundles is connected to the one cooling water circuit and the other cooler bundle is connected to the other cooling water circuit. The two cooler bundles are advantageously arranged next to each other in the housing, wherein the diameter of the housing is large. As a result, the cooler bundles, for construction-related reasons, have no common cross section so that an efficiency-optimized design of the cooler bundles is complicated. During the cooling of the carbonaceous gas, a falling short of the dew point usually occurs so that water precipitates in the cooler. Therefore, for reasons of corrosion resistance, the housing and the cooler bundles are constructed from stainless steel, as a result of which the production costs for the cooler are high.

Furthermore, the use of stainless steel in the cooler on heat transfer surfaces is disadvantageous since the thermal conductivity of stainless steel is sufficiently high only to a limited extent.

SUMMARY OF INVENTION

It is the object of the invention to create a compressor system for a process plant having heat return and a process plant for carbon dioxide gas separation having the compressor system, wherein the process plant has high thermal efficiency and the compressor system is cost-effective in production.

The compressor system according to the invention for a process plant having heat return has a compressor for compressing moist process gas, having at least one compressor stage, and a process gas cooler unit which, for cooling the process gas, is connected downstream to the compressor stage, and has at least one first and one second process gas cooler which is operated with a cooling medium, wherein the process gas coolers have in each case an individual process gas cooler jacket, which is exposed to admission of the process gas, with a process gas cooler bundle accommodated therein and exposed to admission of the cooling medium, are connected directly one after the other on the process gas side, and are designed and can be operated with the cooling medium in such a way that from the process gas cooler which is arranged upstream on the process gas side a predetermined heat flow can be removed from the process gas, as a result of which the thermodynamic state of the process gas between the process gas coolers is located in the region of the dew point front, and the process gas can be cooled to a predetermined temperature by means of the process gas cooler which is arranged downstream. The line in a pressure-enthalpy diagram for the process gas which marks the thermodynamic states of the process gas during which the moisture precipitates in the process gas, is to be understood by dew point front.

According to the invention, the process gas bundles are accommodated in separate process gas cooler jackets so that the process gas coolers are thermodynamically decoupled from each other. As a result, each process gas cooler can be advantageously individually designed with regard to its choice of material and its geometry, especially taking into account a diameter of the process gas cooler jackets which is as small as possible. A lower production cost and a reduced material consumption for the process gas coolers result from this.

If, for example, the process gas is carbon dioxide, then as the moist process gas it is chemically aggressive, as a result of which the materials for the process gas cooler bundles and for the process gas cooler jackets are to be selected as being corrosion-resistant. In particular, stainless steel could come into consideration as corrosion-resistant material. However, a construction of the process gas coolers with stainless steel leads to increased production costs so that the separation of the process gas coolers according to the invention is especially advantageous. Furthermore, different materials can be used for the individual process gas jackets and the individual process gas coolers and are optimally selected with regard to corrosion-resistance, strength, thermal conductivity and costs.

In addition, the process gas coolers can be individually designed in such a way that an optimized flow distribution can be established in the process gas cooler bundles, wherein the narrowest cross section in the process gas cooler jackets is large. As a result, pressure losses in the process gas coolers are advantageously reduced.

The process gas cooler which is arranged downstream is preferably equipped for removing the heat of condensation of the water which precipitates from the process gas and for separating out this water. In addition, it is preferred that the thermodynamic state of the process gas between the process gas coolers is located just ahead of the dew point front. The process gas coolers, by their process gas cooler jackets, are preferably interconnected by two transfer pipes for the parallel conducting of process gas from the process gas cooler which is arranged upstream on the process gas side to the process gas cooler which is arranged downstream. In this case, at least one of the transfer pipes is preferably equipped with a compensator.

At least one of the process gas cooler bundles is preferably arranged eccentrically in its process gas cooler jacket. In addition, it is preferred that at least one of the process gas cooler bundles is of a square-shaped construction and the process gas cooler jacket is of a hollow-cylindrical construction, and that the process gas cooler bundle is arranged in a tilted manner around the longitudinal axis of the process gas cooler jacket for the process gas inflow and/or for the process gas outflow in the process gas cooler jacket. As a result, an enlargement of the inlet cross section and of the outlet cross section of the process gas cooler in question is advantageously achieved, as a result of which pressure loss on the process side in the process gas cooler is reduced.

The process gas plant according to the invention for carbon dioxide gas separation having the compressor system, has a first cooling medium circuit which is equipped for operating the process gas cooler which is arranged upstream on the process gas side, and a second cooling medium circuit which is equipped for operating the process gas cooler which is arranged downstream, wherein the process gas is moist carbon dioxide and the first cooling-medium circuit can be used for re-feeding heat into the process gas plant.

The process gas, which discharges from the compressor stage, is cooled by the process gas cooler which is arranged upstream on the process gas side. Due to the fact that this process gas has achieved its maximum temperature directly after discharging from the compressor stage, the first cooling-medium circuit can advantageously be operated at a high temperature level. As a result, the re-feeding of heat can also take place at a high temperature level, as a result of which the re-feeding of heat is efficient. The re-feeding of heat can be used for heating a consumer water circuit, for example.

Cooling water is preferably the cooling medium. In this case, it is preferred that in the first cooling water circuit, in the inflow to the process gas cooler which is arranged upstream on the process gas side, the temperature of the cooling water is 40° C., and in the outflow from the process gas cooler which is arranged upstream on the process gas side, the temperature of the cooling water is from 120° C. to 160° C., wherein the temperature of the process gas at the process gas inlet of the process gas cooler which is arranged upstream on the process gas side is between 140° C. and 175° C. In addition, in the second cooling water circuit, in the inflow to the process gas cooler which is arranged downstream on the process gas side, the temperature of the cooling water is 24° C. and in the outflow from the process gas cooler which is arranged downstream on the process gas side the temperature of the cooling water is 32° C., wherein the temperature of the process gas at the process gas outlet of the process gas cooler which is arranged downstream on the process gas side is 34° C.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following text, a preferred embodiment of a compressor system according to the invention and a preferred embodiment of a process gas cooler unit according to the invention are explained with reference to the attached schematic drawings. In the drawings:

FIG. 1 shows a schematic view of the embodiment of the compressor system,

FIG. 2 shows a perspective view of the embodiment of the process gas cooler and

FIG. 3 shows a cross-sectional view of the embodiment of the process gas cooler from FIG. 2.

DETAILED DESCRIPTION OF INVENTION

As is evident from FIG. 1, a compressor system 1 has a compressor 2 which is provided for compressing process gas in a process gas plant, wherein the process gas is moist carbon dioxide. The process gas enters the compressor 2 via a compressor inlet 3, is subjected to compression and, in a compressed state, discharges from the compressor 2 at a compressor exit 4.

The compressor 2 is constructed as a multistage compressor and has a first up to a sixth compressor stage 5 to 10. For intercooling, a first process gas cooler unit 11 is provided between the second compressor stage 6 and the third compressor stage 7, a second process gas cooler unit 12 is provided between the fourth compressor stage 8 and the fifth compressor stage 9, and a third process gas cooler unit 13 is provided downstream of the sixth compressor stage 10 and upstream of the compressor exit 4. Therefore, the corresponding process gas cooler unit 11 and 12 and 13 is provided after two compressor stages 5, 6 and 7, 8 and 9, 10 respectively.

The process gas cooler units 11, 12, 13 are formed in each case from two process gas coolers 14 to 19 which are exposed to throughflow by the process gas one after the other. The process gas coolers 14 to 19 have in each case an individual process gas cooler jacket 34, which is exposed to admission of the process gas, and a process gas cooler bundle 35 which is accommodated therein and exposed to admission of cooling water. The process gas cooler bundles 35 of the process gas coolers 14, 16, 18 which are arranged upstream on the process gas side are integrated in a first cooling water circuit 28 and the process gas cooler bundles 35 of the process gas coolers 15, 17, 19 which are arranged downstream on the process gas side are integrated in a second cooling water circuit 31. The first cooling water circuit 28 is formed from an outflow line 29, by which cooling water from the process gas cooler bundles 35 of the process gas coolers 14, 16, 18 is discharged, and an inflow line 30, with which cooling water is directed to the process gas cooler bundles 35 of the process gas coolers 14, 16, 18. The second cooling water circuit 31 is formed from an outflow line 32, from which cooling water from the process gas cooler bundles 35 of the process gas coolers 15, 17, 19 is discharged, and an inflow line 33, with which cooling water is directed to the process gas cooler bundles 35 of the process gas coolers 15, 17, 19. The temperature level of the cooling water in the first cooling water circuit 28 is higher than the temperature level of the cooling water in the second cooling water circuit 31, wherein the temperature of the cooling water in the inflow line 30 of the first cooling water circuit 29 is 40° C. and the temperature of the cooling water in the inflow line 33 of the second cooling water circuit 31 is 24° C.

During operation of the compressor system 1, the process gas at the exit of the second compressor stage 6 and therefore at the inlet 20 of the first process gas cooler 14 of the first process gas cooler unit 11 has a temperature of 175° C., at the exit of the fourth compressor stage 8 and therefore at the inlet 23 of the first process gas cooler 16 of the second process gas cooler unit 12 has a temperature of 149° C., and at the exit of the sixth compressor stage 10 and therefore at the inlet 26 of the first process gas cooler 18 of the third process gas cooler unit 13 has a temperature of 140° C. The first process gas cooler 14 of the first process gas cooler unit 11, just as the first process gas cooler 16 of the second process gas cooler unit 12 and the first process gas cooler 18 of the third process gas cooler unit 13, are designed in such a way that a heat flow is removed from the process gas, as a result of which the thermodynamic state of the process gas between 21 the process gas coolers 14, 15, just as between 24 the process gas coolers 16, 17 and between 27 the process gas coolers 18, 19, is located in the region of the dew point front. The process gas cooler 15 of the first process gas cooler unit 11, just as the second process gas cooler 17 of the second process gas cooler unit 12 and the second process gas cooler 19 of the third process gas cooler unit 13, cools the process gas to 34° C. In this case, the cooling water in the first cooling water circuit 28, in the outflow line 29, is heated to 120° C. to 140° C. and in the second cooling water circuit 31, in the outflow line 32, is heated to 32° C.

In FIGS. 2 and 3, the process gas cooler unit 12 is shown representatively for the process gas cooler units 12, 13 and 14.

The process gas cooler bundle 35 is of a square-shaped design and arranged in the hollow-cylindrical process gas cooler jacket 34. The longitudinal center axis of the process gas cooler jacket 34 is arranged in a parallel offset manner from the longitudinal center axis of the process gas cooler bundle 35 so that the process gas cooler bundle 35 is arranged eccentrically in the process gas cooler jacket 34. In FIGS. 2 and 3, the process gas cooler jacket 34 is arranged in a horizontally disposed manner, wherein the process gas cooler bundle 35 is arranged in a tilted manner around the longitudinal axis of the process gas cooler jacket 34 and is therefore tilted in relation to the horizontal. The process gas cooler jacket 34 of the first process gas cooler 14 and the process gas cooler jacket 34 of the second process gas cooler 15 are formed with two transfer pipes 36 which foam the process gas-side transfer point 21 from the first process gas cooler 14 to the second process gas cooler 15. The transfer pipe 36 is arranged horizontally and the inlet 23 and the outlet 25 are arranged in a vertically extending manner. As a result, the process gas cooler bundles 35 are arranged in a tilted manner around the longitudinal axis of the process gas cooler jacket 34 for the process gas flow through the inlet 23, the transfer pipe 36 and the outlet 25. 

1.-11. (canceled)
 12. A compressor system for a process gas plant having heat return, the compressor system comprising: a compressor for compressing a moist process gas, the compressor comprising at least one compressor stage, a process gas cooler unit connected downstream of the compressor stage for cooling the process gas, the process gas cooler unit comprising at least one first and one second process gas cooler operated with a cooling medium, wherein each of the first and second process gas coolers comprises an individual process gas cooler jacket that is exposed to admission of the process gas, wherein each of the first and second process gas coolers further comprises a process gas cooler bundle accommodated therein and exposed to admission of the cooling medium, wherein the first and second process gas coolers are connected directly one after the other on a process gas side such that the first process gas cooler is arranged upstream on the process gas side and the second process gas cooler is arranged downstream on the process gas side, wherein the first and second process gas coolers are configured to be cooperatively operated with the cooling medium in such a way that: a predetermined heat flow is removable from the process gas from the first process gas cooler arranged upstream on the process gas side, as a result of which a thermodynamic state of the process gas between the first and second process gas coolers is located in the region of the dew point front, and the process gas is capable of being cooled to a predetermined temperature by the second process gas cooler which is arranged downstream on the process gas side.
 13. The compressor system as claimed in claim 12, wherein the second process gas cooler which is arranged downstream is equipped for removing the heat of condensation of the water which precipitates from the process gas and for separating out this water.
 14. The compressor system as claimed in claim 12, wherein the thermodynamic state of the process gas between the process gas coolers is located just ahead of the dew point front.
 15. The compressor system as claimed in claim 12, wherein the process gas coolers, by their process individual gas cooler jackets, are interconnected by two transfer pipes for a parallel conducting of process gas from the process gas cooler which is arranged upstream on the process gas side to the process gas cooler which is arranged downstream on the process gas side.
 16. The compressor system as claimed in claim 15, wherein at least one of the transfer pipes is equipped with a compensator.
 17. The compressor system as claimed in claim 12, wherein at least one of the process gas cooler bundles is arranged eccentrically in its process gas cooler jacket.
 18. The compressor system as claimed in claim 12, wherein: at least one of the process gas cooler bundles is of a square-shaped construction and the process gas cooler jacket is of a hollow-cylindrical construction, and the process gas cooler bundle is arranged in a tilted manner around the longitudinal axis of the process gas cooler jacket for process gas inflow, or for process gas outflow in the process gas cooler jacket, or for both.
 19. A process gas plant for carbon dioxide gas separation, comprising: a compressor system comprising: a compressor for compressing a moist process gas, the compressor comprising at least one compressor stage, a process gas cooler unit connected downstream of the compressor stage for cooling the process gas, the process gas cooler unit comprising at least one first and one second process gas cooler operated with a cooling medium, wherein each of the first and second process gas coolers comprises an individual process gas cooler jacket that is exposed to admission of the process gas, wherein each of the first and second process gas coolers further comprises a process gas cooler bundle accommodated therein and exposed to admission of the cooling medium, wherein the first and second process gas coolers are connected directly one after the other on a process gas side such that the first process gas cooler is arranged upstream on the process gas side and the second process gas cooler is arranged downstream on the process gas side, wherein the first and second process gas coolers are configured to be cooperatively operated with the cooling medium in such a way that: a predetermined heat flow is removable from the process gas from the first process gas cooler arranged upstream on the process gas side, as a result of which a thermodynamic state of the process gas between the first and second process gas coolers is located in the region of the dew point front, and the process gas is capable of being cooled to a predetermined temperature by the second process gas cooler which is arranged downstream on the process gas side, wherein the process gas plant further comprises a first cooling medium circuit equipped for operating the first process gas cooler arranged upstream on the process gas side, and a second cooling medium circuit equipped for operating the second process gas cooler arranged downstream on the process gas side, wherein the process gas is moist carbon dioxide and the first cooling medium circuit is usable for re-feeding heat into the process gas plant.
 20. The process gas plant as claimed in claim 19, wherein the cooling medium is cooling water.
 21. The process gas plant as claimed in claim 20, wherein the temperature of the cooling water is 40° C. in the first cooling water circuit, in the inflow to the first process gas cooler, the temperature of the cooling water is between 120° C. to 160° C. in the outflow from the first process gas cooler, and the temperature of the process gas at the process gas inlet of the first process gas cooler is between 140° C. and 175° C.
 22. The process gas plant as claimed in claim 20, wherein: the temperature of the cooling water is 24° C. in the second cooling water circuit, in the inflow to the second process gas cooler, the temperature of the cooling water is 32° C. in the outflow from the second process gas cooler, and the temperature of the process gas at the process gas outlet of the second process gas cooler is 34° C. 